Gasket and heat shield assembly for a flanged joint

ABSTRACT

A heat shield and gasket assembly has three members including a first heat shield, a second heat shield, and a gasket. Each of the members has a flange portion and the flange portion of the gasket is sandwiched between the flanges of the two heat shields. The flange portion of the gasket is thinner than the flange portions of the heat shields. The thinness of the gasket flange permits it to engage threaded assembly fasteners without compromising the thread integrity of the fasteners.

TECHNICAL FIELD

This invention relates to gaskets and heat shields, and high temperature fluid handling systems, such as engine exhaust.

BACKGROUND OF THE INVENTION

In automobile exhaust systems, a series of pipes are interconnected to conduct the flow of hot exhaust gases from the engine to the tailpipe of the automobile. The pipes consist of a manifold pipe and a pipe leading from the exhaust manifold, which are interconnected with flanged members.

This portion of the exhaust system transmits the exhaust gas directly from the engine to a pipe or passage leading to the catalytic converter. The flanged connection between these pipes radiates a large amount of thermo energy, which can be detrimental to some of the more sensitive components that are positioned near this joint. These components might include electrical wires and pipes carrying fluid for the engine.

The flanged joint is insulated from the surrounding environment by a heat shield that is attached directly to one or both of the flange members and is separate from the gasket, which is compressed between the flange members. The gasket member, of course, prevents the direct leakage of exhaust fumes as the exhaust gases pass through the pipe and the shield protects the environment.

The shield requires extensive machining through the flanges so that the shield might be attached thereto. The heat shield also requires additional work by the assembler to place the shield in the proper location, and if not securely fastened, can result in a rattle or other disturbing noise within the engine compartment.

It has been proposed to provide a single assembly for the heat shield and gasket. One such device is shown in U.S. Ser. No. 09/999,797 filed Oct. 31, 2001, and assigned to the assignee of the present invention.

SUMMARY OF THE INVENTION

It is an object of this invention to provide an improved heat shield and gasket assembly for an automotive system.

In one aspect of the present invention, the heat shield and gasket assembly is formed from three separate components.

In another aspect of the present invention, the heat shield and gasket assembly is formed from a first heat shield, a second heat shield, and a gasket assembly.

In yet another aspect of the present invention, the gasket assembly consists of a thin metal flange and a mesh gasket, which is secured to the metal flange by a rolled edge.

In still another aspect of the present invention, the one heat shield is formed of material, such as stainless steel, having a range of thickness between 0.38 mm to 1.10 mm thick.

In yet still another aspect of the present invention, the other shield member is formed with stainless steel having a thickness in the range of 0.25 mm to 1.10 mm.

In a further aspect of the present invention, the gasket assembly has the flange portion with a thickness in the range of 0.22 mm to 0.18 mm.

In a still further aspect of the present invention, the heat shield and gasket assembly has the components bonded together in a unitary assembly.

In yet a further aspect of the present invention, each of the heat shields and the gasket assembly has flange portions each of which have alignment openings, which are aligned in assembly.

In a yet still further aspect of the present invention, a flange portion of the gasket assembly includes alignment openings having shapes adapted to mount on a threaded fastener without significantly marring the surface of the threaded fastener.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view of a heat shield and gasket assembly incorporating the present invention.

FIG. 2 is a bottom view of the heat shield used in the present invention.

FIG. 3 is a top view of the heat shield shown in FIG. 2.

FIG. 4 is a view taken along line 4—4 of FIG. 3.

FIG. 5 is a bottom view of the other heat shield of the heat shield and gasket assembly.

FIG. 6 is an end view of the second heat shield member.

FIG. 7 is a top view of the gasket assembly.

FIG. 8 is a view taken along line 8—8 of FIG. 7.

FIG. 8A is an enlarged view taken at the circle A in FIG. 8.

FIG. 9 is an exploded view of the heat shield and gasket members prior to assembly.

FIG. 10 is an isometric view of the heat shield and gasket assembly with a portion of an engine exhaust system in place.

DESCRIPTION OF AN EXEMPLARY EMBODIMENT

Referring to the drawings, wherein like characters represent the same or corresponding parts throughout the several views, there is seen in FIG. 1 a heat shield and gasket assembly 10 having a first heat shield component 12, a second heat shield component 14, and a gasket assembly 16.

As seen in FIGS. 2, 3, and 4, the heat shield 12 has a flange portion 18 and a heat shield portion 20. The heat shield portion 20 flares outward from the flange portion 18. The heat shield 12 is preferably made of stainless steel and has a thickness in the range of 0.38 mm to 1.10 mm. The thickness of the flange portion 18 of the heat shield 12 is determined in part by the rigidity required for the heat shield and gasket assembly 10 to provide the necessary protection. The flange portion 18 has two openings 22 and 24.

As seen in FIGS. 5 and 6, the heat shield 14 includes a flange portion 26 and a shield portion 28. The shield portion 28 flares outwardly from the flange 26 and does not have as an extensive length as the shield portion 20 of the heat shield 12. The flange portion 26 has two openings 30 and 32, which align with the openings 24 and 22, respectively, of the flange 18 when the members are assembled. The shield 14 has a thickness considerably less than the thickness of the shield 12. The shield 14 is preferably made from stainless steel with a thickness in the range of 0.22 mm to 1.10 mm. Depending in part by the rigidity required for proper protection within the system. It will also be apparent to those skilled in the art that the shield portion 28 is considerably smaller than the shield portion 20. therefore, the shield portion 28 need not be constructed from a blank having the same thickness as the shield portion 20. In some assemblies, the need for two heat shields may not be required such that the heat shield 14 may be omitted.

As seen in FIGS. 7, 8, and 8A, the gasket assembly 16 has a flange portion 34 and a gasket member 36. The gasket member 36 is secured in an opening 38 formed in the flange portion 34. The opening 38 has a curled edge 39, which is rolled around the gasket 36 to retain the gasket 36 in position. The gasket 36 is preferably a mesh stainless steel ring, which is crushable during assembly to ensure proper sealing of the joint in which the heat shield and gasket assembly is used.

The flange portion 34 has two openings 41 and 42. The opening 41 is substantially I-shaped and the opening 42 as substantially triangular. The openings 41 and 42 are aligned between the openings 24, 30, and 22, 32. The opening 41 has outer edges, which are spaced to be substantially equal to the diameter of the openings 22, 24, 30, and 32. The triangular opening 42 has an outer dimension at the curved apexes thereof, which is slightly less than the diameters of the openings in the flanges 18 and 26. The flange portion 34 of the gasket assembly 16 is preferably made of stainless steel and has a thickness in the range of 0.18 mm to 0.22 mm.

FIG. 9 is a depiction of the heat shield 12, the gasket assembly 16, and the heat shield 14 in an expanded view prior to assembly. When the members are assembled, as shown in FIG. 1, they are bonded together using conventional mechanical or chemical bonding processes. In the embodiment shown, the heat shield 12, gasket assembly 16 and heat shield 14 are spot welded at approximately four locations to form the assembly 10. As can be seen in FIG. 9, the openings 22, 41, and 32 are aligned at assembly and the openings 24, 42, and 30 are aligned at assembly.

After assembly of the heat shield and gasket 10, it may be placed in a system, which includes an exhaust pipe 44, as seen in FIG. 10. The exhaust pipe 44 includes a heavy flange member 46 to which is secured threaded fasteners 48 and 50. The threaded fastener 48 passes through the openings 24, 42 and 30, and the threaded fastener 50 passes through the openings 22, 41, and 32. The openings 24, 30, 22, and 32 are significantly larger than the outer diameter of the fastener 48. The openings 41 and 42 are shaped so engage the outer surface of the fasteners 48 and 50 as the exhaust pipe 44 is placed on the heat shield and gasket 10.

The gasket assembly 16, which contains the openings 41 and 42, is, as pointed out above, made of very thin material. One of the reasons for the thinness is so that the openings 41 and 42 will engage the fasteners 48 and 50 with sufficient force to maintain the assembly 10 in position but without marring the outer diameter of the threads on the fasteners 48 and 50

Also, as pointed out above, the thickness of the flange 18 provides the rigidity for the assembly 10. The members 16 and 14 provide gasketing and heat shielding for the assembly 10. In particular, the gasket 36 will be crushed between the flange 46 and a mating flange in the exhaust system, not shown. The collapsing of the 36 prevents leakage of gaseous fluid between the flanges of the mating components. The heat shields 20 and 28 are positioned to reduce the amount of thermal energy that is radiated from the flange 46 and its mating flange, not shown. 

1. A heat shield and gasket assembly comprising: a first heat shield member having a flange portion and a shield portion, said shield portion extending in a flared relationship relative to said flange portion, said flange portion including spaced openings adapted to accept threaded fasteners without abrasive contact therewith; a second heat shield member having a flange portion and a shield portion, said flange portion having spaced openings adapted to accept said fastener, without abrasive contact therewith and being aligned with said openings in said flange portion of said first heat shield member, said second heat shield member having a material thickness equal to or less than the material thickness of said first heat shield member; and a gasket assembly disposed between said first and second heat shield members, said gasket assembly including a gasket and a flange portion having spaced openings configured to have less with than said openings in said first and second heat shield members and being adapted to engage the outer surface of said threaded fasteners which pass through said openings in said first and second heat shield members, said gasket assembly further comprising: a circular mesh gasket retained in position on said flange portion by a rolled edge of said flange portion, and said gasket flange portion having a thickness substantially less than the thickness of said flange of said first heat shield and equal to or less than the thickness of said flange of said second heat shield; and said first heat shield, said second heat shield and said gasket being bonded to said gasket member in a unitary structure.
 2. The heat shield and gasket assembly defined in claim 1 further wherein: the thickness of said flange portion of said first heat shield is in the range of 0.38 mm to 1.10 mm; the thickness of said second of said flange of said second heat shield being in the range of 0.22 mm to 1.10 mm; and the thickness of said flange of said gasket assembly being in the range of 0.18 mm to 0.22 mm.
 3. A heat shield and gasket assembly comprising: a heat shield member having a flange portion and a shield portion said shield portion extending in a flared relationship relative to said flange portion, said flange portion including spaced openings adapted to accept threaded fasteners without abrasive contact therewith, said heat shield member having a thickness greater that 0.38 mm; a gasket assembly disposed adjacent said heat shield member, said gasket assembly including a gasket and a flange portion having spaced openings configured to engage the outer surface of said threaded fasteners which pass through said openings in said first heat shield members said flange portion having a thickness less than 0.23 mm, said gasket assembly further comprising: a circular mesh gasket retained in position on said flange portion by a roiled edge of said flange portion and having a thickness greater than the thickness of said flange portion; and said gasket assembly and said heat shield member being banded into a unitary structure. 